On-Line Vibration Monitoring Systems

1. On-Line Vibration Monitoring Systems Presented by: Timothy S. Irwin, P.E. Senior Rotating Machinery Engineer M&B Engineered Solutions, Inc. 13 Aberdeen Way Elgin, SC 29045 Email: tsi@mbesi.com 17 February, 2006

2. On-Line Vibration Monitoring Systems Some of today’s subject items: What kind of monitoring system do we need? Do we need protection? Or do we need only monitoring? What options are available for monitoring systems? What kind of failure modes do we need to monitor? Would it be appropriate to reference any industry standards? What type of monitoring/diagnostic software are we or would we be using? What do we need in a specification to get what we want? M&B ESI Timothy S Irwin February 2007

3. On-Line Vibration Monitoring Systems There are a lot of options available today. This is only a portion of what is available on the market. M&B ESI Timothy S Irwin February 2007

4. On-Line Vibration Monitoring Systems What kind of different permanent monitoring systems are available? • Continuous – monitors signals from transducers continuously • Polling – Samples signals from transducers on a pre-arranged schedule • Switches or Transmitters – Sends a signal to the control system • Permanent transducers with remote connections for monitoring/diagnostics Another differentiating item is whether the system provides equipment protection or is purely for monitoring So to determine what level of monitoring we need, we need to know what kind of equipment the system will be installed on. M&B ESI Timothy S Irwin February 2007

5. On-Line Vibration Monitoring Systems Equipment Classifications: • Is the equipment expensive to repair or replace? • Will equipment failure immediately affect operation/production of the plant? • Will equipment failure affect operation/production of the plant after some time? • Will equipment failure create an unsafe condition (EHS)? • What is the equipment reliability history? Answers to the above questions will supply you with the some of the information that may lead to an appropriate justification for an appropriate level of monitoring. What we need to do is set a goal or target for the desired system and then use the following information to develop the specific details, for anything put a full- blown protection system some of the following information may not apply. M&B ESI Timothy S Irwin February 2007

6. On-Line Vibration Monitoring Systems Justification for On-Line Monitoring: • Safety – Inaccessible or dangerous area? • Hazardous Systems – Would failure of the machine cause a hazardous • situation? • Sampling Frequency – Would a failure happen too fast to catch with • routine monitoring? • Manpower – Is there just too much too monitor? • Varying Conditions – Do varying conditions make route monitoring • difficult to analyze? • Monitoring and Analysis Efficiency – Would a permanent system with • analysis capabilities significantly improve • the monitoring and analysis? • Consistency & Repeatability – Are there reasons that are causing difficulty • with consistency or repeatability? M&B ESI Timothy S Irwin February 2007

7. On-Line Vibration Monitoring Systems Continuous vs. Polling: What are the differences and why do we consider them? Continuous: Monitors the desired parameters on a continuous basis and can typically be set up to trip the machine under preset conditions within milliseconds to several seconds as desired. Polling: Monitors the desired parameters on a pre-arranged schedule, the ‘polling’ of the parameter can typically be set from seconds to once per day. This type of system is not typically used for equipment protection but is used for alert and danger alarms for operations personnel and machinery monitoring and diagnostics. M&B ESI Timothy S Irwin February 2007

8. On-Line Vibration Monitoring Systems Continuous vs. Polling: M&B ESI Timothy S Irwin February 2007

9. On-Line Vibration Monitoring Systems Once the level of monitoring is determined (continuous or polling), which parameters should be monitored? We answer that with another question: What kind of component failures are possible? • What is in the machine? – sleeve bearings, REBs, gears, pumps, low-speed, • high-speed, etc. • The answers to the above question will determine the appropriate transducers. • Non-Contact proximity probes • Accelerometers – Low, high, standard frequencies • Velocity Coils • Speed Reference • Phase Reference • Some process parameters may also be appropriate M&B ESI Timothy S Irwin February 2007

10. On-Line Vibration Monitoring Systems What parameters do we want? M&B ESI Timothy S Irwin February 2007

11. On-Line Vibration Monitoring Systems Ron Patrick’s Jet Powered Beetle M&B ESI Timothy S Irwin February 2007

12. On-Line Vibration Monitoring Systems Once the monitoring parameter details (i.e. transducer types and numbers) are determined the actual monitor details can be developed. Various monitor details and options: As a diagnostic oriented professional, let’s take a look at what we want in a monitoring system. This should be for any system whether it is Continuous or Polling • Does the monitor have the necessary frequency span/amplitude range? • Does the monitor/modules have the proper transducer options? • Does the monitor have optional filter settings? • Does the monitor have a buffered output for connecting portable instruments? • (i.e. – this is a short circuit protected test connection) • Does the monitor have a buffered output for every channel? • Does the monitor collect multi-channel simultaneous data? M&B ESI Timothy S Irwin February 2007

13. On-Line Vibration Monitoring Systems Monitor details and options continued: • Does the monitor have a local indication for verification of the • remote indication? • Does the monitor have self-test features? • Can modules be replaced or removed from the monitor while powered? • Can individual channels be turned off when there are known problems • to minimize false indications? • Does the monitor supply an output to a DCS or other remote location? • Can it also supply trip relays for automated protection? • Is the monitor capable of supplying data to a diagnostic software program? • What is the overall signal output of the monitor peak, true-peak, rms? • Are there any system or alarm log capabilities in the monitoring system? • Does the monitor have process parameter capabilities? M&B ESI Timothy S Irwin February 2007

14. On-Line Vibration Monitoring Systems Software details and options: • Can look at ‘live’ or historical data • Has configurable data collection and storage • Has configurable historical data archive capabilities • Has expansion capability for future needs • Can store a new data sample at any time • Has desired plotting capabilities • Configurable alarm settings • ‘Demodulated’ or ‘Enveloped’ tool is available • (with multiple bandwidth options) • Multi-channel simultaneous sampling capability • Has alarm ability for bad data or channel problem • Extended Data collection on alarm M&B ESI Timothy S Irwin February 2007

15. On-Line Vibration Monitoring Systems M&B ESI Timothy S Irwin February 2007

16. On-Line Vibration Monitoring Systems Are you in an industry or process that requires or uses any of the standards that are presently in place? • American Petroleum Institute (API): • API 670 – Machinery Protection Systems • International Standards Organization (ISO): • ISO – 2954:1975 - Mechanical vibration of rotating and • reciprocating machinery -- Requirements for instruments for • measuring vibration severity • ISO – 5348:1998 - Mechanical vibration and shock -- Mechanical • mounting of accelerometers • ISO – 8042:1988 - Shock and vibration measurements – • Characteristics to be specified for seismic pick-ups M&B ESI Timothy S Irwin February 2007

17. On-Line Vibration Monitoring Systems Standards Continued: • ISO – 7919 – Mechanical vibration of non-reciprocating machines – • Measurements on rotating shafts and evaluation criteria • -- Part 1: General guidelines • -- Part 2: Land-based steam turbines and generators in excess of • 50 MW with normal operating speeds of 1500 r/min, 1800 r/min, • 3000 r/min and 3600 r/min • -- Part 3: Coupled industrial machines • -- Part 4: Gas turbine sets • -- Part 5: Machine sets in hydraulic power generating and pumping plants • ISO – 13373-1:2002 - Condition monitoring and diagnostics of machines • -- Vibration condition monitoring -- Part 1: General procedures • ISO – 13373-2:2005 - Condition monitoring and diagnostics of machines • -- Vibration condition monitoring -- Part 2: Processing, analysis and • presentation of vibration data M&B ESI Timothy S Irwin February 2007

18. On-Line Vibration Monitoring Systems Standards Continued: • American Gear Manufacturers Association (AGMA): • AGMA 6000 B96 – Specification for Measurement of Linear • Vibration on Gear Units What else is there? The fact is that there are standards on nearly anything you can think of, do a little digging and you may find a piece of the puzzle that you were missing. M&B ESI Timothy S Irwin February 2007

19. On-Line Vibration Monitoring Systems Now that we have covered: • The type of machinery that we want to monitor • The type of monitoring (i.e. transducers) that is appropriate • The type of monitoring system that is appropriate How do we get what we want installed? It is time to put details into the project • Will the monitor go into an existing cabinet or need a new one? • Will site personnel install the transducers and wiring? • Someone will have to work with IT to get the outputs to the DCS or software M&B ESI Timothy S Irwin February 2007

20. On-Line Vibration Monitoring Systems It is time to write a technical specification • The more detailed the technical specification, the more likely it is that: • You will have the monitoring system that will be functional, reliable, and • with the tools that will make your diagnostic efforts more successful • The installation of the system will be successful and completed in a • timely manner What kind of details are we talking about? Everything that we have discussed M&B ESI Timothy S Irwin February 2007

21. On-Line Vibration Monitoring Systems What do you mean I can’t do this?! Without proper monitoring you may end up with parts that look like this! M&B ESI Timothy S Irwin February 2007

22. On-Line Vibration Monitoring Systems Technical Specification • Transducers – The specification may include but not be limited to: • Temperature range • Amplitude Range • Frequency Span • Linear Range if a proximity probe • Any size constraints • Does it need to be a right angle cable connection • Mounting connections for all transducers M&B ESI Timothy S Irwin February 2007

23. On-Line Vibration Monitoring Systems Technical Specification • Monitoring System – could include but not be limited to: • Desired modules – radial vibration, thrust position, speed, • phase reference, etc. • Equipment protection relays or only monitoring • Frequency span requirements • Filtering option requirements • Do you require local indication for operators • Do you want any self-test features • Type of communication requirements to site DCS or LAN • Simultaneous sampling capability • Short-circuit protected test connections M&B ESI Timothy S Irwin February 2007

24. On-Line Vibration Monitoring Systems Technical Specification • Installation • Generally site/corporate procurement has site conditions and contractor • requirements documentation, but someone still has to put together the • technical requirements for the installation. This could include: • Physical description of installation: • Into existing cabinets • Installation of new cabinets • Wiring installation • Transducer installation – general locations • Depending on how the project is broken down the Owner, • Contractor, and Vendor will all have different responsibilities • within the project. M&B ESI Timothy S Irwin February 2007

25. On-Line Vibration Monitoring Systems Technical Specification • Documentation • Monitor Operation and User Manuals • Transducer System Specification Sheets • Electrical installation drawings • One line drawings • Cabinet installation drawings • Logic drawings • Transducer installation drawings • Bill of materials with all replacement part numbers M&B ESI Timothy S Irwin February 2007

26. On-Line Vibration Monitoring Systems Without proper documentation at installation how do you accomplish the following? • Verify installation locations of the transducers • Verify calibration of the transducer systems • Verify calibration of the monitors • Troubleshoot any identified problems Without the proper documentation and materials up front everyone’s job later will be more difficult and less efficient. M&B ESI Timothy S Irwin February 2007

27. On-Line Vibration Monitoring Systems What about the vendor support of their product? • What kind of warranty are you getting? Are there extension options? • What kind of hardware/firmware/software updates are available to you? • Does the vendor have any kind of field service available? • Does the vendor work with your desired Contractor? Without the proper documentation up front everyone’s job later will be more difficult and less efficient. M&B ESI Timothy S Irwin February 2007

28. THE END ANY QUESTIONS? M&B ESI Timothy S Irwin February 2007